Biostat i OP Manual Rev1 (2)

O p e r a t i n g M a n u a l

Biostat® i Twin Controller

Biostat® i Twin Controller Rev. 1.0 - 0502

Operating Manual micro-DCU - System

Introduction

This document applies to B. BRAUN BIOTECH's digital bench-top BIOSTAT® i Twin controller.. The controller can be used as a universal measurement and control system for spinner flasks, culture vessels and other customized applications.. The characteristics and specifications of the system are subject to change without notice. B. Braun Biotech International GmbH assumes no obligation regard-ing design or future manufacture, respectively, unless otherwise agreed to in writing.

All information in this manual refers to the Biostat® i twin controller together with the equipment available for the BIOSTAT® i fermentor system. As far as other fermentor systems are concerned, the related information is marked correspondingly. The manual considers all standard functions which are implemented at present.. If you happen to find errors or if you miss specific information, please do not hesitate to contact B. Braun Biotech for support.

Assembly, start-up and operation of the fermentor and the peripheral equipment is described in the supplemental operating manuals for those devices. If the Biostat® i twin controller should be con-nected to a host computer, you can contact B. Braun Biotech Inc.for supply of the extra manual "Host-communication", where the protocol for communication with the host computer is described in details.

The Biostat® i twin controller is one example of B. BRAUN BIOTECH's product program of sophis-ticated fermentation and peripheral laboratory equipment. For further information about this device and our complete product program please contact

B. Braun Biotech Inc.

999 Postal Road

Allentown, PA 18109

Phone: 800-258-9000

Fax: 610-266-9319

e-mail: [email protected] WebSite http://www.bbraunbiotech.com

Biostat® i Twin Controller Rev. 1.0 - 0502


Contents Page

INTRODUCTION

1 Design and Functions 4 1.1 General Information 4 1.2 Versions and Extent of Functions 4 1.2.1 General Features of all BIOSTAT® i Twin controller Systems 4 1.2.5 Functions and Correlated Possible Applications of the BIOSTAT® i Twin

controller Systems 6

2 Delivery and Installation 8 2.1 Setup at the Working Place 8 2.2 Connection of Peripheral Units and of the Culture Vessel 8 2.2.1 Connection and Preparation of Peripheral Equipment 8

3 Operation of the controller 9 3.1 Basic and Safety Functions 9 3.1.1 Operating Behavior 9 3.1.2 On/off Switching Error! Bookmark not defined. 3.1.3 Power Failure 9 3.1.4 Menu Structure 10 3.2 Operation of the micro-DCU 10 3.2.1 General Operating Information 10 3.2.2 Basic Menu Structure 12 3.2.3 Operating Information 12

4 Main Function „PROCESS VALUES“ 13

5 Main Function „CALIBRATION“ 14 5.1 Calibration of pH-Electrode 14 5.1.1 Calibration Principles and General Recommendations 14 5.1.2 Operating Display 15 5.1.3 pH - Calibration Routine 16 5.1.4 Notes on Recalibration of the pH-Electrode During the Process 16 5.1.5 Notes about the Calibration Routine 17 5.1.6 Special Notes on Handling of the pH-Electrode 17 5.2 Calibration of the pO2- Electrode 18 5.2.1 Calibration 18 5.2.2 Course of the Calibration Routine 19 5.2.3 Special Notes on the Handling of the pO2-Electrode 20 5.3 Pump Calibration 21 5.3.1 Calibration and Dosing Counter Functions 21

Biostat® i Twin Controller Rev. 1.0 - 0502 1


5.3.2 Operating Display 21 5.3.3 Calibration of Pump Modules of a Pump-100 or Pump-300 Unit 22 5.3.4 Special Notes 22

6 Main Function „Control Loops“ 23 6.1 Extend of Controller Functions of the micro-DCU - system 23 6.2 Controller Operation, General 24 6.2.1 Setpoint Adjustment 24 6.2.2 Operating Modes 24 6.3 Parametrization of Controllers, General 24 6.3.1 Deadband 25 6.3.2 PID - Parameters 25 6.4 PID - Controller Optimization 25 6.5 Temperature Control 26 6.5.1 Temperature Controller 26 6.5.2 Operating Information 26 6.6 Stirrer Speed Control 28 6.7 pH - Control 29 6.7.1 Function Description 29 6.7.2 Operating Instructions 29 6.8 pO2 - Control 31 6.8.1 Modes of Operation 31 6.8.2 pO2 - Controller with One Servo Controller 31 6.8.3 pO2 - Controller with Two Servo Controllers 31 6.8.4 Operating Information 32 6.8.5 Special Notes 33 6.9 Foam Control 34 6.9.1 Function Principles of Foam Control 34 6.9.2 Equipment for the Foam Control 34 6.9.3 Operation of the Foam Control 35 6.9.4 Special Notes 35 6.10 Level Controller 36 6.10.1 Function Principles of Level Control 36 6.10.2 Equipment for the Level Control 36 6.10.3 Operating Information 36 6.10.4 Additional Notes 36 6.11 Controller for Substrate Feed 37 6.11.1 Functional Description 37 6.11.2 Operation of the Substrate Supply SUBS 37 6.12 Airflow - Controller 39 6.12.1 Modes of Operation and Equipment 39 6.12.2 Operating Information 39

7 Main Function „Maintenance“ 40 7.1 Recorders 40 7.1.1 Technical Set-up 40 7.1.2 Operating the Recorder 40 7.1.3 Recorder Configuration 40



7.2 Printers 41 7.2.1 Technical Set-up 41 7.2.2 Operating Information 41 7.3 Host Computers and Connections 43 7.3.1 Technical Set-up 43 7.3.2 Operating Information 43 7.4 Utility Functions 44 7.5 Measurement Ranges 45 7.6 Manual Operation of Digital Outputs, Standard 46 7.7 Manual Operation of Analog Outputs, Standard 47

8 Alarm MESSAGES of System Functions 48

9 Factory Settings 49 9.1 General Information 49 9.2 Factory Settings for Measurement Ranges of Process Values 49 9.3 Factory Settings for Controller Parameters 49 9.4 Example: pO2-Controller with Airflow - Controller and O2 - Enrichment

50 9.4.1 Operation 50 9.4.2 Parametrization 50 9.4.3 Schematic Drawing, Set-up of „Oxygen Enrichment System“ Error!

Bookmark not defined. 9.4.4 Schematic Drawing „Pump Logic of DFC - Software“Error! Bookmark not

defined.

10 Technical Data and Ordering Information 51 10.1 Dimensions 51 10.2 Ordering Information 51 10.3 Technical Specifications 52


1 DESIGN AND FUNCTIONS

1.1 General Information

The Biostat® i twin controller is a digital measurement and control system designed for use with benchtop and pilot scale B. Braun Biotech International GmbH fermentors and can easily be adapted to control other manufacturers fermentors. , The manual below contains the information necessary for attending this measurement and control system. It describes all standard functions available with the software version 3.31).

1.2 Versions and Extent of Functions

1.2.1 General Features of the BIOSTAT® i Twin controller

The digital measurement and control system is contained in a compact benchtop housing:

Dimensions of 450 x 185 x 420 mm (W x H x D) with power supply for the internal compo-nents and for the control of peripherals, such as the Biostat i Interface Box (IFB)

Space saving, stackable design when used with the IFB.

Ability to control a variety of vessels.

DFC-2-board with 80188 microcomputer system, 256 kByte EPROM, 256 kByte RAM (bat-tery buffered)

Operating terminal with film key pad and integrated alphanumeric LCD-display (4 lines with 20 digits)

The sections below give the most import specifications of the different versions.

5-1) If you have a control unit with either an elder or a more actual software version, please contact

B. Braun Biotech International GmbH for a corresponding version of the Operating Manual.


1.2.2 Design and Functions of the BIOSTAT® i Twin controller

Fig. 1: Front view of the Bio-stat i twin controller

Integrated measurement amplifiers and sockets for the following electrodes

Pt 100 - temperature sensor

Ingold pH-electrode

Ingold pO2-electrode

conductive antifoam – electrode

Fig. 2: Rear view of the Bio-stat I twin controller

Sockets, external connections for peripherals:

heating blanket 230 V, max. 1000 W

cooling valve, contact or 24 V DC/AC

remote stirrer speed control, setpoint signal 0 ... 10 V

acid pump or CO2-valve (contact or 24 V DC/AC)

base pump (contact or 24 V DC/AC)

O2 - valve (contact or 24 V DC/AC)

N2 - valve (contact or 24 V DC/AC)


Data outputs for:

computer system (via serial interface RS 422)

printer (via serial interface RS 232)

recorder (via 6 analog outputs 0 ... 10 V)

Software including the following functions:

process display for all process values

digital calibration for electrodes with recalibration functions

temperature measurement and control via triggering of the heating blanket and a cooling water valve

digital measurement of stirring speed, control via remote control unit MCU

pH - measurement and control via triggering external acid and base pumps

pO2 - measurement and cascade control via stirring speed and/or via O2/N2-control valves

foam measurement and control via triggering of an external pump

configurable recorder outputs

communication protocol for host computer system

printer drivers

880 7124 Mains supply 230 V / 50 ... 60 Hz

880 7132 Mains supply 115 V / 50 ... 60 Hz

1.2.3 Functions and Correlated Possible Applications of the BIOSTAT® i Twin controller Systems

The table below gives an overview, which functions and combinations with peripheral devices can be realized with the different versions of the Biostat® i twin controller:

Equipment for BIOSTAT i Twin controller - version

measurement part, accessory - temperature Pt 100 - sensor ● - pH Ingold - pH-electrode ● - pO2 Ingold - pO2-electrode ● - foam conductive electrode ● - level / contents conductive electrode - remote signal-1 connector 0 ... 10 V / 0 ... 20 mA - remote signal-2 connector 0 ... 10 V / 0 ... 20 mA controller - temperature ext. heater / cooling valve or ext. ther-

mostat ●

- stirring speed ext. controller with motor ● - pH - value acid / base pump ●


gasmix ext. O2 - / N2 - control valve ● stirrer ● airflow ● substrate 1 ●

- antifoam or substrate 1 ext. pump ● - level or substrate 2 ext. pump - airflow ext. airflow controller connections - electrical heater ext. temperature controller 230 V, max.

1000 W / heating blanket 230 V, max. 610 W

●

- cooling water valve contact or 24 V AC / DC ● - ext. stirring speed controller setpoint signal 0 ... 10 V ● - massflow controller air setpoint signal 0 ... 10 V - acid pump / CO2-valve contact or 24 V AC / DC ● - base pump contact or 24 V AC / DC ● - antifoam / substr.1 -pump contact or 24 V AC / DC ● - harvest / substr.2 - pump contact or 24 V AC / DC - O2 - valve contact or 24 V AC / DC ● - N2 - valve contact or 24 V AC / DC ● connections for recording / host computer - host computer serial interface RS 422 ● - printer serial interface RS 232 ● - recorder 6 analog outputs 0 ... 10 V ●

.


2 DELIVERY AND INSTALLATION

The following information referrs to the Biostat® i twin controller (Controller) and its con-

nection to the Biostat® i Interface Box (IFB) and Biostat® i vessels

2.1 Setup at the Working Place At a first setup after delivery carefully remove the controller from its packing. Check for

any transport damages at this time

Never connect a unit to any power suppy other than one rated for the systems spe-cific requirements.

1. If the delivery is incorrect, incomplete and/or if transport damages occurred, please contact your supplier, dealer or B. Braun representative immediately and send a claim report.

2. You should place the controller on your work space it in that way that allows for easy ac-cess to all signal and control cables from the culture vessel and from/to the peripheral de-vices.

2.2 Connection of Peripheral Units and of the Culture Vessel

Note the peripheral connections possible with controller. The sockets on front and on rear panel are labelled correspondingly. If existing laboratory equipment should be connected, check the interface specifications in the supplement.

2.2.1 Connection and Preparation of Peripheral Equipment

1. You will have to calibrate the pH-electrode prior to mounting it into the culture vessel. Con-nect the pH-electrode to the controller and proceed as shown in section 5.1.

Connect the IFB, if required for your process, to the controller, If your process requires, the following can be integrated into the IFB – heater jacket outlet(for temperature control of single-walled culture vessels using the

IFB) – gas mixing (oxygen enrichment for fermentation processes or exclusive flow four-gas

mixing for cell culture,.via sparge, overlay or both) – stirrer controller for an overhead drive motor, – three pumps per vessel, for acid, base, antifoam etc. –

Recorders / printers and the host computer system, can also be connected to the controller

2. If existing laboratory devices will be used,, note the specifications in the supplement. Cali-brate the pumps, see section 5.3 for details. After autoclaving the culture vessel, connect all electrodes to their sockets on the front panel of the controller. Connect all lines of the pe-ripheral equipment to the culture vessel. Calibrate the pO2-electrode, see section 5.2 for de-tails.

Adjust all measurement and control parameters. For adjustment of the controller see sec-tion 6. If applicable, adjust the parameters for data transfer to a recorder, printer and/or a host computer as shown in section 7. If not yet done, switch on all units.


3 OPERATION OF THE MICRO-DCU SYSTEM

The controller may be,supplied with a modified basic configuration, additional functions and changed specifications of parameters. For such controller systems you will receive or you can order, respectively, an extra manual or documentation set.

If your controller system does not match with the specifications given below and you do not receive an extra documentation for your system, please contact your B. Braun Biotech rep-resentative or directly the B. Braun Biotech International GmbH

3.1 Basic and Safety Functions

3.1.1 Operating Behavior

The measurement and control system stores all parameters that are adjustable by the operator (set-points, calibration parameters, etc.) in memory with a battery back-up. These parameters will be backed-up when the controller is switched-off and are available again when the unit is restarted for another operation sequence or after power failure.

The controller differentiates between the following different types of power failures.

Switching of the controller „on“ and „off“ via the main powerswitch

Cut-off (shut down) caused by a power failure (mains failure)

3.1.2 Turning the controller ON

The controller can be switched-on or off, respectively, via the main power switch on the front panel. After being switched-on the integrated measurement and control system is in the following defined state of operation :

All controllers are switched off, actuators are in rest (neutral) position

3.1.3 Power Failure

In the”Maintenance” menu, a maximum power failure time (FAILTIME) can be set. See the “Utility Functions” section , on page 44, for details. In the case of a power failure, after being restarted or when power is available again, the system continues all activities as follows:

After a power failure shorter than the time set for the FAILTIME, all controllers will continue with the setpoint active before the power failure.

If the power failure lasts longer than set by the FAILTIME, the measurement and control system will not resume operation.


3.1.4 Menu Structure

The menus of the Biostat i twin controller are divided into main function level and the menu level.

Below you will find the structure for a Biostat i twin controller

Main functions : Menus and related functions

Process Values : Process Values (display of process data in special forms)

Calibration : Calibration function for probes and pumps, as used for - pH - measurement and control - pO2 - measurement and control - ACID - pump - BASE - pump - - level measurement and control LEVEL - substrate control SUBS

Control Loops : DDC controller functions: - temperature control „TEMP“ - stirrer speed control „STIRR“ - pH-control „pH“ - pO2-Control „pO2“ - pump control function „AFOAM“ - pump control function „LEVEL“ - pump control function „SUBS“ - AIRFLOW - control (optional)

Maintenance : Functions for system maintenance and trouble shooting; configuration of in-/outputs, such as : - RECORDER - PRINTER - HOST - UTILITY - MEASUREMENT RANGES - manual operation (DIGITAL OUTPUTS) - manual operation (ANALOG OUTPUTS)

3.2 Operation of the micro-DCU

3.2.1 General Operating Information

1. Select the required main function with the corresponding main function key. The main functions are labelled on the keys. An active main function will be displayed in the first row of the LCD and indicated by an LED in the key.

2. Each main function with the exception of „PROCESS VALUES“ has several subfunctions ar-ranged in a defined order. For example, you will always find the submenu „pH-Sensor“ first whenever you select the main function „CALIBRATION“ or the submenu „Temp“ whenever you select the main function „CONTROL LOOPS“.


3. To scroll throughthe main function menus, repeatedly press the main function key. See above figure for the order of the submenus within each main function. You may change from one main function to another at any time by pressing its main function key.

4. Non-numerical entries in a submenu are used for selecting the state of operation (such as switching over „auto“ ⇒ „man“, „off“ ⇒ „on“). To switch over to an alternate state of opera-tion press the „ALTER“-key. Always confirm the change of an entry by pressing „ENTER“. Otherwise the change will be ignored.

5. If a menu includes more lines than visible on the actual display, either the top line or the lowest line of the information entry will include an arrow „ „ or „ „. You can switch over to additional lines using the cursor-keys. Switching over usually takes place line-by-line, ex-cept with the Process Display, which displays a new page.

6. Access to the menus for adjustment of system functions, like control parameters, is pro-tected by a password. Note the information about the available passwords in the corre-sponding sections below. Passwords are not displayed on the screen when entered.

7. If it is difficult for you to read the LCD, you can change its contrast. This is done with the main function „MAINTENANCE“, in the submenu „UTILITIES“.

Fig. 3: Operating terminal of the measurement and control system


3.2.2 Basic Menu Structure

1st line :

For main functions with several subfunctions (except PROCESS VALUES) the first line identifies the function selected. Data may also be displayed in this line. The headline will al-ways be displayed, even when you scroll down to following lines within the menu.

Different main functions may offer the same headding. Note the LED's in the main function keys, the LED of the main function selected at this time will illuminate.

Example :

TEMP : 37.5 oC

2nd to 4th line :

Information is entered on the lines below the headding. If more than 3 lines are used for dis-play of the parameters, you can scroll down to following lines with the cursor keys. The headding will remain unchanged at this time.

Example :

pO2 : 88,5 % SP : 83,4 % MODE : auto GASM PARAM:

3.2.3 Operating Information Symbol / entry : Meaning, possible input

(in top line) : Additional lines available before the lised displayed. You can scroll

up to above lines with the „ “-key. (in lowest line) : Additional lines to follow within this menu. You can scroll down to fol-

lowing lines with the „ “-key.


4 MAIN FUNCTION „PROCESS VALUES“

The main function PROCESS VALUES menu lists one function per line. The display has no headline. If you scroll down to lines beyond the 4th line even the top line will change.

Process value display, page 1:

TEMP : 42.7 oC STIRR: 1200 rpm pH : 10.3 pH pO2 : 80.4 %


ACID : 32 ml BASE : 200 ml AFOAM: 12 ml LEVEL: 1300 ml


SUBDC: 25.0 ml/m SUBS : 13.0 % FOAM : off LEVEL: off

Optional process value display:

AIRFL: 25.0 l/m EXT_1: 0.0 % EXT_2: 0.0 %

Symbol / entry : meaning, possible input

TEMP, etc. : display of process value with physical unit, such as - process value of analog inputs (Temp, Stirr, etc.) - dosing counter - process values of digital inputs (Foam/Level)

, : Display of additional lines accessible via „ , „-keys AFOAM : Dosing counter for antifoam agent supply LEVEL : Dosing counter of level control pump SUBDC : Dosing counter of substrate pump SUBS : Display of substrate setpoint FOAM, LEVEL : Display of „foam“ or „level“ signal Optional displays: AIRFLOW : Display of airflow rate EXT_1 ... 2 : Display of up to two input signals of remote devices. The entry is in

terms of „0 ... 100 %“ for input signals of „0 ... 10 V“.


5 MAIN FUNCTION „CALIBRATION“

5.1 Calibration of pH-Electrode

5.1.1 Calibration Principles and General Recommendations

The pH-electrode is calibrated by a two-point calibration, which determines the electrode parameters „zero drift“ and „slope“ using buffer solutions. The calibration is done before the electrode is installed in the culture vessel. For calibration, we

For mounting the pH-electrode, please see the corresponding chapter in the „Operating In-formation Culture Vessels for the BIOSTAT® i“ or in the documentation of your specific fer-mentor.

Warning: The calibration buffers can cause burns. Be careful when handling the buffers. You should wear protective gloves during the calibration procedure.

The software of the Biostat i twin controller system calculates the pH-value from the electrode volt-age with regard to „zero drift“ and „slope“, considering the Nernst equation. To compensate for effects of temperature the actual temperature can be entered manually during the calibration.

The pH - electrode is calibrated before mounting into the culture vessel, i.e., prior to its sterilization. The high temperature during the sterilization can cause a shift of the electrodes’ zero. The chemical compounds of the culture broth may also effect the measuring characteristics of the electrode, there-fore the pH-electrode should be calibrated and checked for proper function regularly.

To compensate for changes of the measurement characteristics of the pH-electrode the software of-fers a recalibration function. You can measure the pH-value externally in a sample taken from the process and enter this pH-value into the calibration menu. The system will then recalculate the calibra-tion function and apply the new parameters for the pH-control function.

For measuring the pH-value in such a sample, you should consider the following:

Use only fresh samples. Take care that the sampling method and the containers do not in-fluence the pH-value of the sample

The devices used for external pH - measurement should ensure precise pH-measurement

If the pH - value measured by the Biostat i twin controller and the externally measured pH-value significantly deviate from each other, we recommend to check your remote meas-urement procedure twice rather than changing the calibration parameters. Entering of wrong recalibration parameters into the system can considerably influence the control behavior and the supply of corrective agents, which then will disturb your process.


5.1.2 Operating Display

pH : 7.30 pH TEMP : 23.4 oC man BUFZ : 7.00 pH ok BUFS : 4.01 pH ok

pH : 7.30 pH RECAL: 6.76 pH no ZERO : 4 mV ok SLOPE: 58.4 mV ok


auto/man : When the menu is selected, the cursor is placed at this entry, showing the mode which has been selected previously. Press ALTER to change the temperature compensation mode: - auto: pH-measurement during the process; with temperature compensation using the measured temperature; - man: mode for pH-calibration, with temperature compensation by the temperature which is entered manually

change to „man“ mode for pH-calibration using the temperature la-belled on the buffer bottle for the reference pH-value;

TEMP : display of culture vessel temperature, when in the „auto“ - mode input of the calibration temperature when in the „man“ - mode

BUFZ : input of the pH - value of the zero buffer (as labelled on the buffer bottle for the actual temperature)

ok : confirmation of the calculation of the zero point; after confirmation the cursor jumps to the BUFS - entry

BUFS : input of the pH - value of the slope buffer (as labelled on the buffer bottle for the actual temperature)

ok : confirmation of the calculation of the slope. After confirmation the cursor jumps to the „man/auto“ - entry. The temperature compen-sation will automatically switch over to „auto“ mode

RECAL : display and input of separately measured pH-value for the recali-bration of the pH-electrode

no / yes ... : - no: the electrode will not be recalibrated - yes: the electrode will be recalibrated: After pressing ENTER the cursor jumps to the „RECAL:“ entry. Here you can enter the pH-value measured in a sample taken from the process. After confirmation of the manually entered pH-value with ENTER the system adapts the „zero“ - calibration to the actual conditions.

ZERO : display of the electrodes’ zero in [mV] SLOPE : display of the electrodes’ slope in [mV]


5.1.3 pH - Calibration Routine

1. Press the main function key „Calibration“ once to select the menu for pH-calibration. In the menu the cursor is on the „auto/man“ - entry.

2. To enter the reference temperature labelled on the buffer bottles for the relationship of pH versus temperature of the buffer press „ALTER“ to select „man“ (manual) temperature com-pensation. Confirm with „ENTER“. The cursor jumps to the „TEMP“ - entry.

3. Fill „zero buffer“ of pH 7.0 into a beaker. Place the pH-electrode into the beaker. Measure the temperature of the buffer and enter this as reference temperature into the TEMP entry. Confirm with „ENTER“. The cursor jumps to the „BUFZ“ - entry.

4. Check the reference pH-value of the „zero“ buffer labelled on the bottle for the actual buffer temperature. Enter this pH-value in the BUFZ-entry and confirm with „ENTER“. The cursor then jumps to „ok“ and the system starts an automatic monitoring of the electrode. If the measured signal is constant within the given limits, the system stores the measured voltage as the electrode´s zero. Then the cursor automatically jumps to the BUFS entry.

5. Fill some slope buffer of either pH 4.0 or pH 9.0 (depending on the expected pH-range in the process) into a beaker. Remove the electrode from the beaker with zero buffer, flush with (demineralized) water and place into the beaker with the slope buffer.

Never dry the electrode tip using a paper cloth. This may disturb the calibration.

6. Check the reference pH-value of the „slope“ buffer labelled on the bottle for the actual buffer temperature. Enter this pH-value in the BUFS-entry and confirm with „ENTER“. The cursor then jumps to „ok“ and the system starts an automatic monitoring of the pH-electrode. If the measured signal is constant within the given limits, the system stores this as electrode slope.

7. The cursor automatically jumps to the „man/auto“-entry and switches over the temperature compensation to „auto“-mode. For the pH-measurement the system calculates the pH-value from the electrode voltage using the Nernst equation with regard to the calibrated „zero drift“ and „slope“ and to the temperature measured in the culture vessel.

At step 4 and 6, when the cursor is on the „ok“ entry, you can shorten the automatic monitoring of the electrode. Wait about 10 seconds and press ENTER then. The system stores the actual signal as reference value of „zero“ and „slope“.

5.1.4 Notes on Recalibration of the pH-Electrode During the Process

1. Use a fresh sample taken from the process in such a way, that its pH-value cannot be ef-fected by the sampling procedure.

2. Measure the pH-value using a precise pH measuring system. Enter the value into the corre-sponding entries of the pH-calibration menu, see description of the menu for details.

The „zero“ and „slope“ measured during the first calibration are displayed in the calibration menu until they were overwritten by manually entered values.

By comparing the pH-value measured in the process and the one measured in the sample you can evaluate the accuracy of the pH-electrode. This will also indicate whether the ster-ilization or the process conditions have changed the measuring characteristics of the elec-trode and whether the pH-electrode should be serviced or replaced.


5.1.5 Notes about the Calibration Routine

The automatic monitoring of the electrode at steps 4 and 6 of the calibration routine shown above considers the following references and limits : – measured signal stable within 0.2 % of the measurement range for 60 sec.; – voltage for electrode zero is kept within the range of -30 ... +30 mV; – electrode slope within the range of 54 ... 60 mV/pH

If the measured signal is outside these limits, the system displays an alarm message, such as „**ALARM**, Calibr. out of range, date time“. The calibration has failed and the pH can-not be measured correctly. In this case you should check whether : – all parts are properly connected; – you had followed the above calibration procedure accordingly.

If the error message appears again, the electrode must be serviced or replaced.

The pH-value displayed during the calibration procedure is invalid. The system will display the correct value after completion of the calibration course.

5.1.6 Special Notes on Handling of the pH-Electrode

The electrode has a restricted maximum lifetime that depends on the operating conditions and the application. The electrode should be serviced or replaced, whenever the functional check and the calibration indicate malfunctioning.

You will find more detailed information about handling and mounting of the pH-electrode in the documentation of the culture vessels and their equipment. Also note the documentation delivered with the electrode.

Note: Depending on the type of the delivered pH-electrode, the handling, operation and mainte-nance may differ from the information contained herein. You will find more detailed informa-tion about the electrode, the recommended service periods, the estimated lifetime and proper handling during calibration in the documentation of the manufacturer.


5.2 Calibration of the pO2- Electrode

The pO2 - electrode is calibrated in percentage oxygen saturation, „% pO2“. The calibration is a two-point calibration. Usually a measuring solution without oxygen gives the „zero“-current and a solution saturated with oxygen is defined as „100 % saturated“. The resulting electrode parameters „zero cur-rent“ and „slope“ are used to calculate a calibration function for pO2-measurement of the process.

When used for pO2-measurement in a fermentor the pO2-electrode will be calibrated in the culture vessel after the sterilization. For measurement of the electrode´s „zero“ the culture medium can be gassed with nitrogen to replace any oxygen in the medium. Supply of air or a specific gas mixture re-quired for the process up to saturation with oxygen gives the electrode´s „slope“, 100 % pO2.

The calibration menu for the pO2-electrode displays the actual „pO2“ as percentage saturation „% pO2“, the zero current and the slope. This allows a simple function control of the pO2-electrode.

5.2.1 Calibration

Operating display

pO2 : 89.3 % TEMP : 23.4 oC auto NITR : 0.0 % ok AIR : 100 % ok

pO2 : 89.3 % AIR : 100 % ok ZERO : 3.6 nA SLOPE:160.3 nA


auto/man : When the menu is selected, the cursor is placed at this entry, showing the mode being previously selected; press ALTER to change the temperature compensation mode: - auto: temp. compensation using the measured temperature; - man: temp. compensation using the temperature which is entered manually

TEMP : Display of vessel temperature, when in the „auto“ - mode; input of the calibration temperature when in the „man“ - mode

NITR : Display of zero pO2; ok : Confirmation of the calculation of the zero point; after confirmation

the cursor jumps to the AIR - entry; AIR : Display of the pO2 - value at optimum aeration of the culture me-

dium for slope calculation ok : Confirmation of the calculation of the slope. After confirmation the

cursor jumps to the „auto/man“ - entry. The temperature compen-sation will automatically switch over to „auto“ mode

ZERO : Display of the electrodes’ zero in [nA] SLOPE : Display of the electrodes’ slope in [nA]


5.2.2 Course of the Calibration Routine

It is necessary to polarize a pO2-electrode the first time it is used or when it has been dis-connected from the amplifier for more than 5 to 10 minutes. Polarization may take up to 6 h (shorter, only if the electrode has been disconnected for a few minutes).

In a culture vessel the pO2-electrode will be calibrated after sterilization. Any effects of the sterilization on the electrode, such as impacts of heat or chemical reactions of compounds of the medium with the membrane or the electrolyte will be considered for the calibration.

For „zero“ calibration you can measure the pO2 after the autoclave sterilization, before air (or gas containing oxygen) is supplied. Since the heating of the medium causes the dis-solved gasses to be exhausted, the pO2 should be near zero, then. The measured signal can be identified as „0 % pO2“.This method will be precise enough for most of the applica-tions.

If a very precise „zero“ measurement is required, the medium can be gassed with an oxy-gen-free gas (N2 of 99.8 % purity, for instance) to replace any remaining dissolved O2.

The electrode „slope“ will be calibrated when the culture medium is saturated with oxygen.

5.2.2.1 Steps of Operation for Calibration

Do not supply air or any gas containing oxygen before the zero pO2-calibration is done. For „zero“ calibration using the supply of oxygen-free gasses, gas the medium with the intended gas and wait until the measured pO2 is constant near „0 %p pO2“.

1. Press main function key „Calibration“ twice to enter the pO2-calibration menu. The cursor will be in the „auto/man“ entry. If the mode is „man“ press ALTER to change into „auto“-mode for temperature compensation considering the actual temperature in the culture ves-sel. Confirm your selection with ENTER, the cursor jumps to the „NITR“ - entry.

2. Confirm the measured value as „NITR : 0,0 %“ with ENTER. The cursor then jumps to „ok“.

The system starts an automatic monitoring of the electrode. After autoclaving and prior to supply of any gas containing oxygen the measured NITR-value should be near „0 % pO2“. If the measured electrode´s zero current is constant near „0 nA“ (within the given limits), the system stores this as zero reference. The cursor automatically jumps to the AIR entry.

3. Gas the culture vessel with air or the gas mixture provided for the process at the required flow rate. Confirm „AIR : 100 pO2“ with ENTER. If the slope reference should not be 100 % pO2, enter the intended value into the AIR entry and confirm a changed input with „ENTER“.

The cursor then jumps to „ok“. The system starts an automatic monitoring of the electrode. If the measured signal is constant within the given limits, the system stores this as slope. The cursor automatically jumps to the „auto“-entry.

During the process the system calculates the pO2-value from the measured electrode`s cur-rent with regard to calibrated „zero“, „slope“ and the temperature. Since the calibration re-fers to the reference conditions (flow rate and type of gas) applied for the calibration, the ac-tual pO2 measured can exceed 100 % O2, depending on the flow rate and kind of gas sup-plied.


5.2.2.2 Additional Notes about the Calibration Routine

The pO2 - measuring value displayed during the calibration course is invalid. The correct process value is only available after running the calibration.

The automatic monitoring of the electrode after confirmation of the NITR and AIR entries considers the following references and limits: – measured signal stable within 0.2 % of the measurement range for 60 sec.; – current for electrode zero is kept within the range of NITR 0 ... +15 nA; – electrode slope within the range of AIR: 25 ... 200 nA

If the measured signal is beyond these limits, the system displays an alarm message, such as „**ALARM**, Calibr. out of range, date time“. In this case the calibration routine has failed and the pO2 cannot be measured correctly. However, the system will accept the calibrated „zero“ and „slope“. You should repeat the calibration and check whether : – all parts are properly connected; – you had followed the above calibration procedure accordingly.

If the error message appears again, the electrode must be serviced or replaced

At step 4 and 6 of the calibration routine, when the cursor is on the „ok“ entry, you can shorten the automatic monitoring of the electrode. Wait about 10 seconds and press ENTER then. The system stores the actual signal as reference value of either zero and slo-pe.

5.2.3 Special Notes on the Handling of the pO2-Electrode

The pO2-electrode is subject to wear and tear, due to the impacts of heat during sterilization and due to possible chemical reactions of compounds of the culture medium with the mem-brane or the electrolyte. Such effects may alter the membrane structure, ingredients of the media may bind to the membrane or ions may permeate into the electrolyte. Over time, t his will change the measurement characteristics Therefore the electrode has a restricted maximum lifetime that depends on the operating conditions and the application.

The electrode must be serviced whenever the electrode measures currencies exceeding the limits given above, while no oxygen is present, or the electrode shows a slow response.

The service of the pO2-electrode is restricted to – cleaning of the anode – replacement of the membrane module – refilling with fresh electrolyte

We recommend that you should refill with new electrolyte after about 5 sterilizations or after about 6 weeks of use for measurement. Depending on the physical/chemical properties of the culture solution it may be necessary to do this more often.

If replacing the electrolyte does not improve the measurement characteristics, the anode must be cleaned and/or the membrane module must be replaced. See the information con-cerning maintenance and service in the documentation of the electrode´s manufacturer.

You will find detailed information about installing the pO2-electrode in the documentation of the culture vessels and their equipment. However you should note, that the required opera-tion and maintenance measures may differ from the information herein, depending on the type of the pO2-electrode delivered. Specific information about proper handling of the elec-trode, the recommended service periods and the estimated lifetime is available in the documentation from the manufacturer.


5.3 Pump Calibration

5.3.1 Calibration and Dosing Counter Functions

To monitor the corrective solution consumption the Biostat i twin controller can totalize the dosing times of the pumps and use them as process values. For this it converts the dosing times into deliv-ered volumes with regard to the specific flowrates of the pumps. This is possible for the following pumps and operation modes :

1st pump: supply of an acid, mode „ACID“ 2nd pump: supply of alkaline solution, mode „BASE“ 3rd pump: for supply of antifoam agent, mode „AFOAM“ 4th pump: substrate supply or harvest pump for level control, mode LEVEL 5th pump: for substrate supply, mode „SUBS“

The flowrates can be calculated automatically from the measured running time of the pumps and the delivery of the pumps during the calibration. The flowrates can also be entered directly via the operat-ing terminal. You can zero the dosing counters for the pumps at any time via the operating terminal.

Since the calibration and dosing counter functions are the same for all pumps, only those for the acid pump will be described in details herein.

5.3.2 Operating Display

ACID : 1280 ml MODE : calib strt TOTAL: 200 ml FLOW : 1.2 /m


ACID : Display of acid volume delivered; the counter will be set to zero : - at switching on the unit with the mains switch; - when switching the operation mode over from „calib“ to „total“

for the other pumps instead of ACID the following entries are shown : BASE : Display of delivered volume of alkaline agent („BASE“) AFOAM : Display of delivered volume of antifoam agent „AFOAM“ LEVEL : Display of actual value of the LEVEL dosing counter SUBDC : Display of the substrate volume delivered MODE : Enter mode of the dosing counter :

- calib: calibration of flow rate (delivery) of the pump; - total: dosing counter active; switching from „calib“ to „total“ mode sets the counter to zero.

strt/stop : Enter operation mode „start/stop“ of the pump calibration routine. This entry is only active in the „calib“-mode.

TOTAL : When switched into „calib“ - mode, the delivered volume can be entered herein

FLOW : Display of actual pump delivery or input of delivery rate. It is possible to enter a delivery rate manually at any time


5.3.3 Calibration of Pump Modules of a Pump-100 or Pump-300 Unit

1. Place a piece of tubing of suitable length with one end into a beaker filled with water, mount the tubing into the pump head and place the outlet end into a measuring beaker. The tubing must be the same size that will be used for medium transfer (such as 1.6 x 1.6 or 3.2 x 1.6 mm).

2. To avoid errors in calibration due to the clearance volume of the tubing, activate the pump manually until the tubing is completely filled.

3. Press the main function key „Calibration“ several times to select the menu of the pump which should be calibrated (ACID, BASE, AFOAM or LEVEL). Move the cursor to line „MODE : total“. Press the ALTER-key once to change to „MODE : calib“. Confirm with „ENTER“. Then the cursor jumps to „strt“.

4. Press „ENTER“ to start the pump for calibration. At the same time the entry at „TOTAL“ will be deleted. The pump delivers liquid for a certain period. The system automatically switches over to „stop“ while the cursor remains in this entry. Confirm „stop“ with „ENTER“. Then the cursor jumps to „TOTAL“.

5. Measure the volume delivered into the measuring beaker and enter the measured volume in entry „TOTAL“. Confirm your input with „ENTER“.

Now the system calculates the flowrate, which will then be displayed. Again, confirm with „ENTER“ . The cursor jumps to entry „MODE“. The operation mode automatically changes from „calib“ to „total“. The existing entry of „TOTAL“ will be deleted.

If you want to calibrate another pump, select the corresponding menu using the main function key „Calibration“ and repeat the steps shown above.

5.3.4 Special Notes

You must use tubing of the same size for calibration and delivering the addition solution (tubing size Ø 1.6 x 1.6 or 3.2 x 1.6 mm, for instance). Otherwise the system will calculate the dosage using wrong calibration parameters.

You can do the calibration before start-up and sterilization, however, recalibration is possi-ble at any time using tubing of the same size as connected to the storage bottles.

The dosing counter will be set to zero when the Biostat i twin controller is switched-off. When disabling the controller with „stop“ the dosing counter will not be set to zero but will continue with the actual value after restart.

During a fermentation run you should handle the assemblies with special care to prevent loosening the connections to the culture vessel or damages of the tubings.

Caution: Acid or alkaline agent used for pH-control can cause burns, when the tubing get loose and the agents are released unintentionally.

Damages to the tubing can cause the corrective solutions, and in turn the vessel contents to be contaminated.


6 MAIN FUNCTION „CONTROL LOOPS“

All control loops in the measurement and control system operate as DDC controllers. The controllers are implemented as PID controllers, setpoint controllers or on/off controllers and adapted to the con-trol loops concerned. Depending on the connected actuators the control output is either continuous or pulsewidth-modulated. Both single- and split-range control operation are possible. The controller structure (P-I-D) can be parametrized according to the task, if necessary.

The controller functions possible with the Biostat i twin controller are shown below. The controllers can be operated in different modes. Switching between the operating modes is carried out with bum-pless transfer.

OFF : controller switched off with defined output AUTO : controller in operation CASC : controller operating as servo controller in cascade mode

In the operating display you can enter the actual value and the operating mode. Controller parametri-zation is accessible by entering the required password in the „PARAM“ - entry. Then the parametriza-tion menu appears for adjustment of PID parameters and deadband.

The Biostat i twin controller can be connected to a host computer and run in remote operation mode. Setpoints and operating modes of the individual controllers are then determined by the host computer. In this mode the Biostat i twin controller operating terminal will be locked against inputs.

6.1 Extend of Controller Functions of the micro-DCU - system

Temperature controller : PID cascade controller with pwm-splitrange outputs for heat-ing / cooling

Stirrer controller : PID controller with analog output for motor control

pH controller : PID controller with pwm-split-range outputs for the acid & base pump

pO2 controller : PID cascade controller for one or two servo controllers. Servo controller(s) can be the - stirrer controller - substrate dosing controller - Gasmix controller for control valves for supply of N2 and O2 or - as an option: airflow controller

Foam controller : On/off (cycle/delay time) controller for antifoam

Level controller : On/off (cycle/delay time) controller for harvest pump

Substrate controller : Setpoint controller for an external continuous substrate pump or, as an alternative, for an internal pump, which has no control function (ACID/BASE or AFOAM/LEVEL)

Optional controllers:

Airflow controller : Setpoint controller for a massflow controller

Gasmix : Setpoint controller for pulse-width modulated splitrange out-puts for N2 and O2 of a separate Gasmix unit (optional equipment). This controller is not displayed.


6.2 Controller Operation, General

All DDC controllers are operated in almost the same way. The „Control Loops“ menu of each of the controllers has two different displays:

The settings for the setpoints and the operating modes of the controllers are done in „Oper-ating Displays“, which is directly accessible. If more than 3 lines are required for displaying the settings of a controller, you can scroll up and down to following lines showing additional parameters using the cursor keys „ , “.

Any settings not required for routine operation, will be made using the parametrization func-tions.. The „Parametrization Displays“ are only accessible via a two-digit password The sec-ond page is accessible via a password.

6.2.1 Setpoint Adjustment

Setpoints are entered and displayed in the SETP entry. Entered values must be within the measuring range of the variable. Values exceeding the measuring range will be ignored.

6.2.2 Operating Modes

Operating modes are entered and displayed in the MODE - entry. Modes are selected via the ALTER - key. Some controllers only allow specific operating modes. If a selected mode is not plausible for the controller, the inputs will be ignored. – In „off“ - mode the controller is inactive; the output adapts to a defined position (corre-

sponding to the neutral position of the actuator). – In „auto“ mode the controller is active. Setpoint values can be altered via SETP. – In „casc“ mode the controller operates as a servo controller in a cascade control loop.

The setpoint value is specified by the master controller; it cannot be adjusted via SETP.

6.3 Parametrization of Controllers, General

For optimum adaptation of the DDC controllers to the control loops of the fermentor, you may change the important control parameters of the different controllers via the parametrization displays :

DEADB : Deadband adjustment (only for PID controllers) XP, TI, TD : PID-Parameter (only PID controllers) MIN, MAX : Controller output limits

Within a controller display the parametrization display is only accessible via the required password. The Biostat i twin controller is pre-programmed with control parameters that ensure stable opera-tion of the control functions.

Under normal circumstances changing the control parameters is not necessary, with the ex-ception of those control loops which are strongly influenced by the process, such as pH and pO2 control. For the control parameters preset in the factory see the tables on page 49.

Note: Because the corresponding sections below show the passwords, this manual should only be available for personnel, who are qualified and authorized to enter pa-rameter displays and change the given settings. Inadequate changes of the parame-ters can cause malfunctioning of the BIOSTAT i Twin controller.


6.3.1 Deadband

For PID controllers a deadband can be adjusted. For actual values that vary stochastically, a prede-fined deadband allows for more stable control with minimized actuator changes. The controller output remains constant or is set to zero (specific feature of pH - controller) if the control deviation is within this deadband. In the case of splitrange controller outputs, a deadband can prevent the controller out-put from oscillating (such as alternating acid-alkali titration by the pH-controller).

The deadband is adjusted in the entry DEADB, it is the percentage [%] of the measurement span of the actual value and is symmetrical to the adjusted setpoint.

Example for pH control: – measurement range pH = 2 - 12 pH, measurement span 10 pH – adjusted deadband 1% = ± 0.1 pH, adjusted setpoint 6.0 pH

Here the control is inactive at an actual value within 5.9 pH - 6.1 pH. The acid pump will be activated when the actual value exceeds the upper limit, the alkaline agent pump will be ac-tivated when the actual value falls below the lower limit.

6.3.2 PID - Parameters

The PID controller can be optimized via the following PID parameters : XP : Proportional range in % of measurement range (P-section) TI : Reset time in seconds (I-section) TD : Rate time in seconds (D-section)

The PID parameters can be adjusted in the corresponding entries. The digital controller implemented operates according to the positioning method. Setting individual PID parameters to zero determines the control principle. For easy optimization of the controllers you can change the parameters during operation. Set the parameters for the controller functions as follows:

to work as : required PID - parameter

P-controller : TI = 0, TD = 0 PI-controller : TD = 0 PD-controller : TI = 0 PID-controller : all PID - parameters have defined set values

6.4 PID - Controller Optimization

You will need some detailed knowledge about the control theory for optimum adaptation of a PID con-troller to the corresponding control loop. For detailed information about proven adjustment rules you may refer to any standard literature. Therefore the following specifications are only general guidelines:

The D section (TD) should only be activated in the case of stable actual values, since the controller output will change rapidly if the actual values are varying stochastically. This would lead to an unstable control.

As a rule the TI : TD ratio should be 4 : 1.

In the case of a periodically oscillating control loop you can increase Xp and/or increase TI/TD to minimize or even prevent ocillation.

If an actual value responds to the setpoint too slowly after a setpoint jump or if the actual value shows a continuous change (drift), you can decrease Xp and/or decrease TI/TD


6.5 Temperature Control

The temperature control system is specifically designed for operation of a heating blanket and a cool-ing valve at single-walled culture vessels of the BIOSTAT® i - fermentor system.

6.5.1 Temperature Controller

The temperature is maintained is a single-loop PID controller. The vessel temperature is the reference input. The controller output activates the cooling valve and the heater in split-range operation via pulsewidth-modulated outputs. As a special feature, the master controller can be switched from PD - operation (which is active at start-up) to PID - operation when approaching the setpoint. This can al-most completely eliminate overshooting of the control.

6.5.2 Operating Information

Operating display page 1 :

TEMP : 37.5 oC SETP : 33.4 oC MODE : auto PARAM: _


TEMP : Display of actual value SETP : Display or input of controller setpoint MODE : Display and input of control mode:

- auto: automatic operation according to given setpoint; - off: controller is switched off, outputs are in operating state

PARAM : Enter 2-digit password „19“ to have access to the controller parame-ters. When entering the password it will not be shown in the display.


Operating display page 2, with cursor within the upper 4 lines :

TEMP : 37.5 oC MIN : -100 % MAX : 100 % XP : 10.0 %

Operating display page 2, with cursor moved down to the lowest line :

TEMP : 37.5 oC TI : 300 s TD : 75 s DEADB: 00.0 %


MIN : Display and input of minimum controller output limit. For the tem-perature controller this parameter limits the output for „cooling“

MAX : Display and input of maximum controller output limit. For the tem-perature controller this parameter limits the output for „heating“

Note : The values for „MIN“ and „MAX“ depend on the individual meas-urement range. If the measurement ranges are changed, the „min“ and „max“ values for the outputs are changed correspondingly and cannot be exceeded

XP : Enter proportional range TI : Enter integral portion (reset time) TD : Enter differential portion (delay time) DEADB : Enter dead band , : More lines are available via the „ , “ - keys


6.6 Stirrer Speed Control

The stirrer speed control acts as a setpoint controller for the motor controller , located in the IFB. It transmits an analog control signal for the motor controller to setting the stirrer speed. In conjunction with the pO2-controller the stirrer speed controller can be servo controller in the pO2 - cascade control loop.

For 10 l - culture vessels of the BIOSTAT® i the speed must be limited to max. 600 rpm. At higher speeds the culture vessel and motor can become unstable.

The stirrer speed cannot be limited by factory setting of the system. The full speed range must be available if the motor is mounted to any other culture vessel.. Therefore always consider the max. permissible speed when adjusting the setpoint!

Operating display:

STIRR: 750 rpm SETP : 750 rpm MODE : auto PARAM:


STIRR : Display of actual value SETP : Display or input of controller setpoint MODE : Display and input of control mode:

- auto: automatic operation at given setpoint - casc: cascade operation. The controller is servo controller and triggers the output of the master controller; - off: the controller is switched off, outputs are in operation state

PARAM : Enter 2-digit password „19“ for access to the controller parameters

Operating display page 2, with cursor within the upper 4 lines :

STIRR: 750 rpm MIN : 004.2 % MAX : 100.0 % XP : 200.0 %


STIRR: 750 rpm TI : 5 s TD : 0 s DEADB: 000.0 %

Symbol/entry : meaning, possible input

MIN, MAX : limiting controller output to minimum or to maximum XP : Enter proportional range TI : Enter integral portion (reset time) TD : Enter differential portion (delay time)


DEADB : Enter dead band

6.7 pH - Control

6.7.1 Function Description

The pH - controller of the Biostat i twin controller is a software function that acts as a PID controller. This function triggers the corrective solution pumps for supply of acid and alkaline agent in split-range mode via two pulse width-modulated outputs. This allows for a reversible control of both pumps. If gaseous CO2 should be applied for pH - control instead of acids (as often applied in tissue cell cul-ture), the output of the controller can be connected to a CO2 - control valve.

The acid and base signals will remain switched-off as long as the deviation remains within the pa-rameter dead bands. This will prevent unnecessary supply of acid or alkaline agent to the culture broth and will limit the consumption of these corrective agents (this is also true for CO2, if applied).

6.7.2 Operating Instructions

6.7.2.1 Setting the Setpoint and Controller Mode

Operating display page 1 :

pH : 7.25 pH SETP : 7.10 pH MODE : auto PUMP : ACID/BASE

Operating display page 2:

pH : 7.25 pH MODE ; auto PUMP : ACID/BASE PARAM:


pH : Display of actual value in the headline SETP : Display or input of controller setpoint MODE : Display and input of control mode:

- auto: automatic operation with the given setpoint; - off: controller is switched-off; outputs are in the operation state

PUMP : Display and selection of the required pump(s) - ACID/BASE: both acid and base pump are operated - ACID/-----: the acid pump is operated but not the base pump; thus the base pump is free for use as the substrate pump - -----/BASE: the base pump is operated but not the acid pump; thus the acid pump is free for use as the substrate pump

PARAM : Enter 2-digit password „19“ for access to controller parameters; during entry the password will not be displayed


6.7.2.2 Parametrization

Parametrization display, with cursor within the upper 4 lines :

pH : 7.25 pH XP : 30.0 % TI : 30 s TD : 0 s

Parametrization display page 2, with cursor moved down to the lowest line:

pH : 7.25 pH TI : 30 s TD : 0 s DEADB: 0.5 %


XP : Input of proportional range TI : Input of integral portion (reset time) TD : Input of differential portion (delay time) DEADB : Input of dead band , : More lines are available below; move over using the „ , “ - keys


6.8 pO2 - Control

6.8.1 Modes of Operation

The measurement and control system of the Biostat i twin controller includes a pO2-controller for universal use. Thus the pO2 control function can be applied as required for the intended process. It is possible to adapt the pO2 control to specific process requirements. In particular the following control strategies can be performed :

pO2-control by operating a single process value. These servo controllers can be selected: – stirring speed (STIRR) – substrate supply (SUBS) – gas supply by mixing of 2 gasses (GASMIX) – gas supply using the optional massflow controller (AIRFL)

pO2-control by operating two process values. The same servo controllers can be selected.

6.8.2 pO2 - Controller with One Servo Controller

In the pO2 control using one servo controller the pO2 controller acts as the master controller. Its output directly operates the input of the servo controller. In standard configurations the pO2-controller oper-ates either the stirrer speed controller, the substrate supply or the Gasmix controller, respectively.

By use of the Gasmix servo controller two gasses can be mixed, such as N2 and O2, for instance. For this the Gasmix controller operates a valve for O2 supply and a valve for supply ofO2 in spliltrange mode via pulse-width modulated outputs. This method is often applied for bubble free gas supply to the culture medium via a membrane aeration system.

6.8.3 pO2 - Controller with Two Servo Controllers

For the pO2-cascade control serial operation can be selected. In this case the pO2-controller operates two servo controllers one after another, according to their prior-ity. In the pO2-controller you can predefine a „min/max“ range for each servo control-ler. The pO2-controller operates the individual servo controller, as long as the corre-sponding setpoint is within its „min/max“ range. If you set the reverse „min/max“ - settings you will get the reverse control .

When the pO2-control is switched on, the output of the pO2-controller operates the servo controller 1 (CASC1) with the given setpoints within the range of the preset „min/max“ set-tings. As far as selected, the servo controller 2 receives the „MIN“ setpoint of the pO2-controller.

If the setpoint signal reaches the „MAX“ value defined for the servo controller of priority 1, the output of the pO2-controller will automatically switch over to the setpoint input of servo controller 2 (CASC2). The delay time for swiching over is 5 min (default setting) and can be modified. Then the following setpoints will be transmitted:

servo controller 1 : at predifined MAX output for CASC1 servo controller 2 : controlled output of pO2-controller

If the O2-consumption of the process is reduced again, the controllers return to the previous control principle in reverse order.

This control principle allows for an accurate pO2-control during the process, the pO2 can be kept con-stant even at larger variations of the O2-consumption without any manual control required. Above this the PID-parameters of the servo controllers 1 and 2 can be set independently from each other to pro-vide an optimum adaptation of the controls to the behaviour of the control system.




Operating display, cursor in the first line:

pO2 : 88.5 % SETP : 83.4 % MODE : auto CASC :STIRR AIRFL

Operating display, cursor in the last line:

pO2 : 88.5 % MODE : auto CASC :STIRR AIRFL PARAM:


pO2 : display of actual value in the headline SETP : display or input of controller setpoint MODE : auto: automatic operation with the given setpoint;

off: controller is switched-off; outputs are in the operation state. CASC : display or selection of servo controller 1 and, if necessary, servo

controller 2 STIRR : the output of the pO2-controller operates the setpoint of the stirrer

controller. The operation mode of the stirrer speed controller will automatically switched over to „casc“ -mode.

SUBS : the output of the pO2- controller operates the setpoint of the sub-strate 1 controller. The mode for the substrate 1 controller will be set to „casc“ automatically.

GASM : the pO2-controller operates the setpoint of the gasmix controller. The controller is not shown on the display

AIRFL : the output of the pO2 controller operates the setpoint of the airflow controller. The operating mode is automatically swiched over to „casc“. The AIRFL servo controller can only be selected, if the op-tional massflow controller is available.

PARAM : Enter 2-digit passwort „19“ for access to controller parameters


6.8.4.2 Parametrization

Parametrization display, page 1, with cursor within the upper 4 lines :

pO2 : 88,4 % DEADB: 0.5 % HTIME: 5 min STIR MIN : 0 %

Parametrization display, page 1, with cursor in the lowest line :

pO2 : 88,4 % MAX : 100 % XP : 100 s TI : 100 s

Parametrization display, page 2 , with cursor in the lowest line :

pO2 : 88,4 % XP : 100 s TI : 100 s TD : 0 s


DEADB : Enter dead band HTIME : display or input of the delay time for switching over from cascade 1

to cascade 2 STIR, etc. : selection of servo controller using the ALTER key STIR : display / setting of the controller parameters for the stirrer control-

ler while used as servo controller SUBS : display / setting of the controller parameters for the substrat con-

troller while used as servo controller GASM : display / setting of the controller parameters for the gasmix control-

ler while used as servo controller AIRFL : Display and adjustment of the controller parameters related to the

servo controller „Airflow“; only if this servo controller is available (Option)

XP : Enter proportional range TI : Enter integral portion (reset time) TD : Enter differential portion (delay time) , : More lines are available below; move over using „ , “ - keys

6.8.5 Special Notes

For the pO2-controller two sets of parameters are internally available. Access is only possi-ble to the PID - set, which has been activated before within „Mode“.


6.9 Foam Control

6.9.1 Function Principles of Foam Control

When foam has contact with the foam sensor for longer than 6 seconds the foam amplifier releases a limit value signal, which is the input signal for the foam controller. The sensitivity of the foam meas-urement amplifier can be adjusted in the display of the foam controller. The delay time prevents erro-neous activation of the foam control and supply of antifoam agent caused by short time contact or splashes of the liquid against the probe.

The controller output operates an externally connected „Antifoam“ pump. The pump is switched-on and off periodically as long as foam is detected (sensor signal = on). Running time and the cycle time (= dosing time + delay time) for intermittent operation can be entered via the controller display.

The amount of antifoam agent delivered by the pump depends on the hose dimensions. After calibra-tion of the pump using the corresponding calibration function a dosing counter displays the delivered volume.

The antifoam pump connected to the Biostat i twin controller can be used as substrate pump, if the foam control function is not required.

6.9.2 Equipment for the Foam Control

The following parts are necessary for setting up this version of the foam control system:

Height adjustable, single conductive foam probe. Measuring principle is conductivity meas-urement; the stainless steel parts of the culture vessel act as the opposing electrode

Integrated peristaltic pump in the BIOSTAT® I supply unit.

Autoclavable bottles for antifoam agent with connectors and tubings for sterile supply


6.9.3 Operation of the Foam Control

Operating Display, page 1:

FOAM : off MODE : auto chg CYCLE:01:30 m:s PULSE:00:05 m:s

Operating Display, page 2, with cursor in the lowest line:

FOAM : off SENSI: 3 PULSE:00:05 m:s PUMP : AFOAM


FOAM : Display of actual signal of sensor FOAM in the headline; the function displayed (FOAM/SUBS) will automatically switched over according to the preselected function

MODE : Enter controller mode : - auto: controller is active, automatic operation; - off: controller is switched-off; outputs are in the operation state; 1. Place cursor at „auto“ or „off“, respectively 2. Press ALTER to switch over the mode and confirm with ENTER

CYCLE : Enter cycle time in „Minutes:Seconds“ [mm:ss] PULSE : Enter pump running time in „Minutes:Seconds“ [mm:ss] SENSI : Enter probe sensitity; 4 levels of sensitivity are adjustable PUMP : Display and selection of the pump which is connected to the control-

ler: - AFOAM: the antifoam controller operates the antifoam pump - -----: the antifoam controller does not operate the antifoam pump. The antifoam pump can be used for the substrate supply function.

6.9.4 Special Notes

If chemical foam control using commercially available antifoam agents (such as greases, oils, oil-water-emulsions, silicone-oils, paraffines) is applied, you should note that these agents can affect the growth of the cells and cell metabolism. Therefore the amount of agent supplied to a culture vessel should be minimized.

Dosing of antifoam agent should only be activated, when foam has contact with the probe. Adjust sensitivity of the probe in such a way that bubbles, foam residues or culture medium splashing against the probe will not activate the controller. Adjust cycle time long enough to differentiate between splashing or short contact of foam or medium caused by stirring and/or aeration and longer contact with foam.

The reference potential for the foam electrode is provided via the Pt-100. Thus the foam measuring system only works if both the foam electrode and the Pt-100 are mounted into the top-plate of the culture vessel of the BIOSTAT® i.


6.10 Level Controller

Taking samples during a fermentation run will reduce the volume of media in the culture vessel, there-fore you may need to add media to the culture vessel from time to time. You will also supply media or specific substrates for fed-batch or continuous processes. This can cause the maximum working vol-ume of the vessel to be exceeded and the surplus volume needs to be removed.

The level control function of the Biostat i twin controller provides a monitoring of the volume in the culture vessel. In addition you can automate the removal of surplus medium as well as the supply of medium and specific substrates, in order to keep the volume in the culture vessel constant.

6.10.1 Function Principles of Level Control

The insertion depth of the level probe determines the controlled filling volume of the culture vessel. Therefore you will need to gauge the capacity of the vessel and determine the insertion depth of the probe. When the culture medium comes into contact with the probe, the level amplifier generates a digital signal, which is the input signal for the level control function. You can adjust the sensitivity of the amplifier to consider the conductivity of the medium and to avoid unintended controller activities due to contact of foam with the probe or by splashing of liquid against the probe.

The level amplifier offers the two modes „HARV“ (harvest) and „FEED“. In the „HARV“ mode the level controller output operates the „LEVEL“ pump, as long as the level signal is „on“. The pump acts as harvest pump. In the FEED - mode, it operates the pump, when the level signal is „off“. Then the pump acts as dosing pump. The pump operates at running and delay times, which can be adjusted in the corresponding operating display. The amount of medium which is removed or supplied, depends on the running time and the hose dimensions. If the pump is calibrated using the corresponding pump calibration function, the dosing counter displays the exact delivery volumes.

6.10.2 Equipment for the Level Control

The following parts are necessary for setting up this version of the level control:

The level probe is a height adjustable, single conductive electrode. Measuring principle is conductivity measurement; the stainless steel parts of the vessel act as the opposing elec-trode

Integrated peristaltic pump in the BIOSTAT® I supply unit.

Containers for samples or autoclaveable bottles for substrate, with connectors and tubings. If you need to remove any culture medium contamination-free you can use autoclaved sam-pling bottles as required for the supply of antifoam agent or nutrient solution.


You will operate the level controller in the same way as the antifoam controller. See the above section for details.

6.10.4 Additional Notes

To adjust the level probe at the required height for control of a certain filling volume, you'll have to measure the vessel capacity, taking into account the displacement of accessories n the vessel, such as vessel electrodes.

You should label the volumes on the vessel, as far as necessary. However, you should note, that high stirring speeds and/or intensified gassing of the culture can produce an in-creased level in the culture media, compared to the level at low stirring or gas supply..


6.11 Controller for Substrate Feed

6.11.1 Functional Description

The supply unit supports an external continuous pump intended for substrate feeding. The controller does not use feedback of the actual speed of the pump. The display of the process value „SUBS“ rep-resents the controller´s setpoint. The amount of substrate supplied with the pump depends on the run-ning time and the hose dimensions. If the pump is calibrated using the pump calibration function (refer to the pump calibration instructions in section 5.3), the dosing counter displays the exact deliveries.

You can operate the substrate controller using a time dependent setpoint profile. Such a profile can have step changes and ramp changes with max. 10 segments and be started and stopped at any time.

6.11.2 Operation of the Substrate Supply SUBS


Operating display

SUBS : 20 % SETP : 020.0 % MODE : auto PUMP : SUBS

Operating Display with cursor in the lowest line:

SUBS : 20.0 % MODE : auto PUMP : SUBS PARAM: __


SUBS : Display of setpoint of substrate controller SETP : Display or input of the setpoint for the pump delivery (flow rate) MODE : Enter controller mode :

- auto: automatic operation with the given setpoint; - off: controller is switched-off; outputs are in the operation state; - casc: substrate controller is switched to cascade operation for the pO2-controller; i.e. the pO2-controller delivers the setpoint for the substrate controller - profil: automatic operation using a defined setpoint profile

PUMP : Display and selection of the connected pump : - SUBS: the controller operates an external continuous pump; - ACID: the substrate controller operates the ACID pump, i.e. the pump is not used by the pH-controller; - BASE: the substrate controller operates the BASE pump, i.e. the pump is not used by the pH-controller; - AFOAM: the substrate controller operates the AFOAM pump, i.e.the pump is not used by the AFOAM-controller; - LEVEL: the substrate controller operates the LEVEL pump, i.e. the pump is not used by the LEVEL -controller

PARAM : Access to the controller parameters via 2-digit password „19“


6.11.2.2 Parametrization of the Substrate Dosing Function SUBS, Input of a Setpoint Profile

Parametrization display page 1

SUBS : 15.0 % MIN : 000 % MAX : 100 % TIME0: 0:00 SP : 10 %


TIME1: 1:10 SP : 15 % TIME2: 2:00 SP : 20 % TIME3: 3:15 SP : 35 % TIME4: 4:00 SP : 40 %_


TIME5: 4:50 SP : 55 % TIME6: 5:30 SP : 70 % TIME7: 6:00 SP : 80 % TIME8: 6:15 SP : 90 %


TIME9: 7:00 SP : 90 %


MIN : Display and input of the minimum controller output limit MAX : Display and input of the maximum controller output limit TIME0...9 : Display and input of the time for max. 10 profile changes SP : Display and input of the setpoints for the profile changes

Additional notes

If the time for the first breakpoint is not set to „00:00 h:m“ the system uses the current set-point for the start of a profile.

In a program for a setpoint jump (step change) both setpoints can have the same time.

When a profile is defined and started for pO2-control, correlating active profiles for „SUBS“ will be stopped automatically. The controller will be switched over to „cascade“-mode.


6.12 Airflow - Controller

6.12.1 Modes of Operation and Equipment

Airflow controllers allow an automatic continuous control of the air supply according to the oxygen consumption in the process. This is a more sensitive and efficient method for air supply than by the „on/off“ operation of the pO2-solenoid valves usually applied.

Airflow controllers are separate massflow controller modules. The airflow controller will be installed in the inlet airline of the culture vessel and can be directly connected to the Biostat i twin controller. It will be triggered by an analog setpoint signal. For equipment of your system you will need the follow-ing parts:

„Biostat i twin controller - 300“ with software version 3.3 or later

For the BIOSTAT® A, depending on the size of the vessel and the intended gas flow: – airflow - controller 3 l/min, cat.-no. 880 7400, or – airflow - controller 10 l/min, cat.-no. 880 7418,

A suitable laboratory stand or the optional rack for the BIOSTAT® A, cat.-no. 880 8007 (as required for the placement of the airflow control modules at the working place)


Operating display :

AIRFL: 3.00 slpm SETP : 3.00 slpm MODE : auto PARAM:_

Parametrization display :

AIRFL: 3.00 slpm MIN : 0 % MAX : 100 %


AIRFL : display of actual flowrate SETP : entry of setpoint for the flowrate MODE : enter controller mode :

- auto: automatic operation with the given setpoint; - off: controller is switched-off; outputs are in the operation state;.

PARAM : access to controller parameter, enter 2-digit password „19“ for this MIN : „min“ limit of controller output MAX : „max“ limit of controller output


7 MAIN FUNCTION „MAINTENANCE“

7.1 Recorders

7.1.1 Technical Set-up

Two types of recorders are available for the Biostat i twin controller, the Arucomp SK 10 recorder with digital display and a Hartmann und Braun

Arucomp SK 10 recorder with analog display, Hartmann und Braun

7.1.2 Operating the Recorder

The recorder is contained in an extra housing and will be connected to the corresponding socket „Recorder“ of the micro - DCU.

Below an overview on the most important (default) settings for connection to a fermentor, like the BIOSTAT® A is given. Additional information about individual functions and the ad-justment of operation parameters can be found in the Operating Manual 2) of the recorder.

7.1.3 Recorder Configuration

The controller system includes a recorder output board with plug connection. The socket „Recorder“ offers 4 analog outputs 0 ... 10 V for connection of a 6-channel dot printer. It is possible to assign up to 4 process values to these outputs. The signal ranges of the outputs are fixed and correspond with measurement range for the process values.

Operating display page 1:

Recorder CHAN1:TEMP CHAN2:STIR CHAN3:pH

Operating display page 2, with the cursor in the lowest line :

Recorder CHAN4:pO2


CHAN1 : Enter process value for recorder output channel 1. Select other process values with the „ALTER“ key. Confirm selection with ENTER. Moving over with a cursor key without ENTER will ignore your selection

CHAN2..4 : see CHAN1 , : More lines are available. Move over using „ , “

2) Included in the documentation set if part of the system configuration on delivery. Otherwise

available on request. Please contact B. Braun Biotech International GmbH for this.


7.2 Printers


Connection of a protocol printer to the controller allows for easy on-line recording of a „hardcopy“ of the fermentation run. Thus the course of important parameters can be monitored and/or unexpected events can easily be detected.

The printer can be a standard matrix printer with serial interfaces and small fonts. It will print the pa-rameters numerically into a corresponding table. The protocol will include the data of the PROCESS DISPLAY and the following parameters (see example of a protocol below) :

Date, time of the print (showing the time of an event during the fermentation run)

All process values

Alarm messages


7.2.2.1 Connection of a Printer

1. Connect the printer to the RS 232 interface of the Biostat i twin controller (socket „printer“). Note the information for connecting and presetting the printer in the operating manual of the device.

2. Switch over to the menu for the printer settings, see the menu, the tags and the information about the entries below.

3. Set the cycle time for the output of data.

4. Start the printout. Starting and stopping is possible at any time during the process.

7.2.2.2 Setting the Operation Parameters

Operating display :

Printer CYCLE: 20 min MODE :start PARAM: __


CYCLE : Enter cycle time for printout of one line of the protocol in the table. Possible cycle times are in the range of 1 ... 60 minutes.

MODE : Enter operation mode of the printer, select via the „ALTER“ - key. : - stop: no data will be printed - start: printout of data is active

PARAM : Enter 2-digit password „19“ for access to interface parameters.


7.2.2.3 Parametrization of the Printer

„Printer Parameters“ display:

Printer SPEED: 9600 bd DATA : 8 bit STOP : 1 bit

„Printer Parameters“ display:, with cursor in the lowest line :

Printer DATA : 8 bit STOP : 1 bit PARTY: no


SPEED : Enter signal transfer rate within the range of 300..19,200 baud; de-fault is 9,600 baud

DATA : Enter number of data bits: 7 ... 8; default is 8 STOP : Enter number of stop bits: 0 ... 2; default is 1 PARTY : Enter kind of parity bit: „even“, „odd“, „no parity“; default is „no“


7.3 Host Computers and Connections


The Biostat i twin controller can be connected to host computer via the integrated serial interface RS 422. Operation principle is „Multidrop“ - operation using a 4-wire network. The protocol is compati-ble with the protocol of the measurement and control system DCU. It includes measurement values and setpoints at fixed order. You can adjust the interface parameters via a password - protected op-eration display. User definable transfer rates are within 300 ... 19.200 baud.


1. Connect host computer to the controller via the serial interface RS422 „Host“ on the rear of the unit. Check the documentation of you host computer for necessary settings.

2. Switch over the operating terminal to the menu for host communication.

Operating display:

Host ADR : 2 PARAM: XX


ADR : Display of BIOSTAT® B - address PARA : Enter 2-digit password „19“ for access to interface parameters

Operating display „Parameters":

Host ADR : 2 SPEED: 9600 bd DATA : 7 bit


Host DATA : 7 bit STOP : 1 bit PARTY: even


ADR : Enter controller - address 1 ... 16 SPEED : Enter transfer rate within 300 ... 19,200 baud; default is 9,600 baud DATA : Enter number of data bits: 7 ... 8; default is 7 STOP : Enter number of stop bits: 0 ... 2; default is 1 PARTY : Enter kind of parity bit: even, odd, no parity; default is „even“


7.4 Utility Functions

Within the „Utility“ - menu you can find and reset, if necessary, some general system settings, such as the „date“ or „real time clock“. The display also shows the implemented software version and any spe-cific configuration, if applied.

Operating display, page 1:

Utility DATE :17.12.1990 TIME :14:30 h:m VERS : 3.01


Utility CONFG:BA01D FAILT:02:00 h:m CONTR:alter

Operating display, page 2, with cursor in the lowest line :

Utility FAILT:02:00 h:m CONTR:alter PARAM: ___


DATE : Display or input of date TIME : Display or input of time (system clock) VERS : Display of software version

CONFG : Display of configuration identification3 FAILT : Display or input of the failtime for power failures. If a power failure

is shorter than the preset „failtime“, the process will be continued with the given settings of all parameters. If the power failure takes longer, the system behaves like being switched off with the mains switch after return of the power supply.

CONTR : Select contrast of the LCD - display using the „ALTER“ - key. PARAM : Entry of password for access to the configuration parameters; this is a

special password only available for authorized service personnel.

3 Example for configuration code. Note the entry in the display of your system if questions arise

concerning the implemented extent of functions or for trouble shooting, when calling our hotline.


7.5 Measurement Ranges

The menu shows the measurement ranges of the process values. Setting of the parameters is possi-ble in a submenu, which is also protected by a password.

Only authorized service personnel is allowed to change the measurement ranges!


Meas. Ranges PARAM:___

Page 2 of the Operating Display, with cursor within the upper 4 lines :

Meas. Ranges PV :TEMP MIN : 0.0 % MAX : 100.0 %


PARAM : Enter password „753“ to select the second page of the display. PV : Display or input of a process value. For selecting another process

value use the „ALTER“ - key. MIN : Display or input of the starting point (lower limit threshold) of a

measurement range. MAX : Display or input of the ending point (upper limit threshold) of a meas-

urement range.

On delivery the following measurement ranges of process values are adjusted as default (you should note that these settings can be different for the Biostat i twin controller deliv-ered to you, for connection to a BIOSTAT® A and/or to other fermentors):

Process value Limit of measurement range Physical unit lower limit upper limit

TEMP : 0.0 100.0 degC STIRR: 0 1,200 rpm pH : 2.00 12.00 pH pO2 : 0.0 100.0 % ACID : 0 500 ml BASE : 0 500 ml AFOAM: 0 500 ml LEVEL: 0 10,000 ml SUBDC: 0 10,000 ml SUBS: 0 100 % AIRFL: 0 10.00 l/m EXT1..2: 0 100.0 %


7.6 Manual Operation of Digital Outputs, Standard

The menu „Manual Operation - Digital Outputs Std.“ is used for service support. It displays the state of the digital outputs of the system. Within this menu no inputs are possible.

Menu display :

MAN OP DIG OUT STD 1: a off 2: a off 3: a off 4: a o 5: a o 6: a off

Symbol / entry : Meaning

1 ... 16 : digital output, channel 1 ... 16 a, etc. : display of mode of output: a : „automatic“: internal function acts on output, i.e. controller o : „operating state“: no internal function acts on output s : „sterilization“: sterilization program acts on output

(only available for control systems with sterilization programs, i.e. not valid for BIOSTATA, for instance)

h : „host“: host computer connected acts on output off/on : display of state of:

- off: output statically switched off - on: output statically switched on

0 ... 100 : display of state of pulse-width modulated output : - 0: output switched off - 100: output fully (100%) switched on - 20: output switched on in pulse-with modulated state. In this example the output is switched on at a rating of 20%. The cycle time (pulse - pulse) depends on the controlled system and is in the range of 5 ... 10 s


7.7 Manual Operation of Analog Outputs, Standard

The menu „Manual Operation - Analog Outputs Std.“ is used for service support. It displays the state of the analog outputs of the system. Within this menu no inputs are possible.

Menu display :

MAN OP ANA OUT STD 1: a o 2: a o 3: a o 4: a 50 5: a 10 6: a 90

Symbol / entry : Meaning

1 ... 8 : analog output, channel 1 ... 8 a, etc. : display of mode of output: a : „automatic“: internal function acts on output, i.e. controller o : „operating state“: no internal function acts on output 0 ... 100 : display of state of output: 0 : output switched off (voltage of 0 V) 100 : output switched on (voltage of 10 V)


8 ALARM MESSAGES OF SYSTEM FUNCTIONS

When they occur, alarms will be displayed within an extra alarm menu, showing date and time of the alarm. If several alarms occur, they will be stored in an internal buffer, which can hold up to ten alarms. A single alarm message will dissappear after pressing any main function key. For more than one alarm, the next alarm will be displayed afterwards.

Examples of alarm displays :

** ALARM ** Power failure 22.01.01 14:33

** ALARM ** HEATER failtime 22.01.01 14:33

Symbol/entry : meaning, possible input

Heater failure : Display of heater alarm (malfunction of heater) Motor failure : Display of a motor alarm (malfunction of motor or motor control) Power failure : Display of general power failure of mains supply Calib. out of range : Display of a warning (error message) of the probe calibration; see

description of the „Calibration“ menu for details BUFRAM read error : System error; a software reset has been applied or the battery is

malfunctioning EEPROM read error : System error; the parameters specific for the system cannot be proc-

essed; not all functions are available (system partly out of order)

How to Answer Alarm Messages :

1. If the process continuous although an alarm has occured, check which kind of alarm it is and whether the process has been interfered. Disturbances of the process may be indicated at the chart paper of the recorder or the printout of the printer. You may continue the proc-ess, if possible or need to interupt it.

2. If the alarm has stopped the fermentation run, you may try to continue by restarting the fer-mentor. Check at the display and at the chart paper of the recorder or the printout of the printer at which state of operation the fermentation run has been stopped, which kind of alarm it is and whether the process has been interfered.

3. At malfunctioning of the related device of fermentor and if the system cannot be restartet: – check all adjustments for the related component – readjust given setpoints, etc., if necessary.

For information about the system parameters adjusted in the factory see section 1, „Factory Settings“ on next page.

4. If it is impossible for you to restart the fermentor system by this, and in any case one of the system errors „BUFRAM read error“ or „EEPROM read error“ occurs you should contact your B. Braun service representative or directly the B. Braun Biotech International GmbH.


9 FACTORY SETTINGS

9.1 General Information

For the Biostat i twin controller - the following system parameter settings are configured in the fac-tory. The parameters can be changed according to specific requirements. In the case of unintended changes of the parameters or for a general reset you can recreate the original state.

9.2 Factory Settings for Measurement Ranges of Process Values See the definitions given in section 7.5. Additional information is in preparation. You will re-

ceive such setting information together with the Biostat i twin controller or on special re-quest. Please contact B. Braun Biotech International GmbH for this.

9.3 Factory Settings for Controller Parameters

CL-Tag MIN [%]

MAX [%]

DEADB [%]

XP [%]

TI [s]

TD [s]

RAMP [%]

TEMP --- --- 0 7 1000 250 ---

STIRR 0 100 0 --- --- --- 20.0

pH --- --- 0.5 30 30 0 ---

pO2/STIRR 0 100 0,5 150 100 0 ---

pO2/AIRFL 0 100 0,5 100 50 0 ---

pO2/SUBS -100 100 0 120 60 0 ---

pO2/GASMIX -100 100 0,5 5 200 0 ---

AIRFL (option) 0 100 --- --- --- --- ---


9.4 Example: pO2-Controller with Airflow - Controller and O2 - Enrichment After switching on the pO2 - controller first operates the AIRFL - controller. At this time the

GASMIX - controller receives the „MIN“ setting assigned in the pO2 - controller.

If the setpoint setting of the AIRFL - controller reaches its maximum, the output of the pO2 - controller switches over to the setpoint input of the GASMIX - controller, see fig. on the next page. The AIRFL - controller receives the „MAX“ setting defined in the pO2 - controller. For control of the pO2 the GASMIX - controller operates a 3/2-way valve for supply of air and O2.

9.4.1 Operation

pO2 : 88.5 % SETP : 83.4 % MODE : auto CASC : AIRFL GASMX


pO2 : Display of actual value des Istwertes SETP : Display and input of the controller´s setpoint MODE : Display and input of the controller´s operating mode:

- auto: automatic operation with the given setpoint; - off: controller is switched off; outputs are in operating state

CASC : Display and selection of servo controller 1 and 2: AIRFL : The pO2 - controller operates the setpoint of the Airflow - controller GASM : The pO2 - controller operates the setpoint of the Gasmix-controller.

Note that the Gasmix controller is invisible in the operating display PARAM : Access to the controller parameters via 2-digit password „19“

9.4.2 Parametrization

Parametrization display page 1 :

pO2 : 88,4 % DEADB: 0.5 % HTIME: 5 min GASMX MIN : 0 %

Parametrization display page 2 :

pO2 : 88.4 % MAX : 100 % XP : 100 s TI : 100 s


DEADB : Display and input of the Totzone („Dead band“) HTIME : Display and input of delay time for switching from cascade 1 to 2 AIRFL, etc. : Selction of the servo controller using the ALTER key AIRFL : Display and input of the parameters for the Airflow - controller GASM : Display and input of the Parameter for the Gasmix - controller


Technical Data and Ordering Information

9.5 Dimensions Space requirements : W x H x D about 450 x 185 x 420 mm

Weight : about ____ kg

9.6 Ordering Information

Cat.-no. Version, specifications, additional notes

BIOSTAT i Twin controller

880 843/0 Mains supply 115 V / 50 ... 60 Hz

Information about the availability of Biostat i twin controller for use with other fermentor systems is available on request.



9.7 Technical Specifications System set-up : microprocessor-board (DFC-2) with integrated measurement

amplifiers and actuator controls; measurement amplifiers according to the specifications of the version Biostat i twin controller 100, 200 or 300 microprocessor-system with 80C188 processor, offering - 128 kByte RAM, 128 kByte EPROM, - 8 analogue inputs, 8 analogue outputs, - 8 digital inputs and 16 digital outputs automatic restart after power down with adjustable FAILTIME

Operating panel : illuminated LCD-Display with 4 lines x 20 characters film keyboard with 20 keys

Temp.-control : temperature sensor Pt 100, measurement range 0 ... 100 degC; digital PID-controller with split range outputs

Stirrer-control : RPM-measurement with Hall sensors; measurement range 0 ... 1,200 rpm; digital PID-controller for motor controller

pH-control : pH-electrode with pasty electrolyte (Ø 12 mm); digital sensor calibration; measurement range 2 ... 12 pH PID-controller with split range outputs for acid / alkali; dosing counter for acid-/alkaline agent - pump

pO2-control : pO2-Electrode (Ø 12 mm); digital sensor calibration; measurement range 0 ... 100 % pO2 (with reference to oxy-gen saturation of the measurement solution); digital PID-cascade controller

Antifoam-Control : digital on/off controller and dosing counter for use with - conductive foam sensor; - antifoam agent pump

Level control : digital limit controller and dosing counter for use with - conductive level sensor; - harvest or substrate pump

Substrate pump control : control of max. 2 feed pumps via pwm - outputs - adjustable delivery rate 0 ... 100% - dosing counters for feed pumps

Recorder connection : 4 analogue outputs 0 ... 10 V - configurable assignment of parameters to channel

Protocol printer connection : via serial interface RS 232 C - with configurable printing intervals and process variables for protocol

Host connection : via serial interface RS 422, protocol of measured values, set points and controller mode

Documents

Biostat i OP Manual Rev1 (2)